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I'm back baby!
Its been a while, but at last, here are some progress pics.
I finished my Jet Pack, installed the voice amp speaker (& some other bits) and put a sturdy locking system on the jet pack door. Here it is attached & some pics showing the door.
Next-up, the girthbelt. I bolted the Girth-belt, Ammo pouches, Cod, Thighs & Holsters into a 1 piece belt, now it all holds in place. Thanks Jango 5204 for the great instructional pics. I'm contemplating weather to attach the Girth belt to the Flack Vest. This would hold it in position, but might also pull down on the Vest.
If anyone has attached their Belt to the Vest let me know how it turned out.

After (too) many attempts, I have installed the visor, & am happy with it.
Some guys seam to get this right first go (I'm looking at you Tubachris), but not for me. I have a pile of ALMOST perfect visors, and one that will do as a back-up.
Installing the visor ruined the primer coat I had applied, so more sanding & paint & sanding later, and its ready, again.

As soon as I get a wind-free day I'll be painting the blues onto the helmet.

I attach the top of my codpiece to the bottom of my vest with a snap. It keeps the whole vest down (including the collar from cutting my neck) and keeps my holsters from sagging with the weight of my westars.

Thanks again for the feedback guys, I'm on the home stretch now.
I have added 5 press studs to the Girth Belt & Flack Vest to keep them in place, looking good.

Now everything from the neck down is finished, just the Helmet to go.
I spent a couple hours masking the cheek curves for painting, but I'm concerned it will look rough when painted, so I did some research and have a new approach.

I have traced the curve of each cheek, and am going to cut the shapes from adhesive vinyl. The hard part is to then position the vinyl exactly in the right position, and I now know how! The trick is to wet the cheeks with soapy water, this allows the vinyl to slide a little when positioning, then when its in the desired position, use a small squeegee to remove the excess water & leave for a few hours to dry. I have had a practice & it looks like this will do the job.

There is one other item I'll be working on after the helmet is done, the new Man Of War Arena Jet Pack! I couldn't resist, I expect to receive it in the next week or so. I'll be putting my current JP in the Cargo Hold some time soon.

Shots as promised.
The first is the 'from the neck down' finished Jango.
The 2nd shot shows my first attempt to mask the cheeks. I have removed the tape & I'm going to try the vinyl masking right now!
I'll let you know how it goes!

Well its time to get back onto the Jango.
I took a break after my Jango Helmet rolled off my workbench and received multiple hairline cracks.
What a great excuse to upgrade to a Cruzer produced Cold Cast BKBT helmet,
it should arrive early next week.
Mmmm...Cold Cast......
I have removed all the wiring & servo from my 'old' helmet (see pic) & have a new visor ready & waiting.
I'll post a pic of the Cold Cast BKBT as soon as it arrives.

I have been going over cold cast threads here at THD and cant find a good (or any) tutorial on how to bring out the best finish.
I read of Duragilt, steel wool & sanding sponges, but not the process.
Can anyone point me to any info that might already be posted, or drop a post here if you have the answers.
Cheers!

I would recommend polishing the whole thing with the sanding sponges and then tape off and paint. No need for primer because you'll already have a smooth surface the paint can stick to. Then hit the unpainted parts with the steel wool once the paint has dried. I'd even lightly hit the painted areas with the steel wool to get all the dust specks off, and then buff the paint back out for some shine with some rubbing compound. It's exactly what I did with the one I painted. http://www.thedentedhelmet.com/showthread.php?t=30075

OK, I have the clips to hold the helmet liner in place.
The bolts to hold the fan are in.
The 'ears' have been aligned, gaps filled, holes drilled & it all bolts in place.
The Servo is set in place & has been successfully tested.
I have finished the Key holes & almost finished the Visor cut-out.

I got some chicago screws for the visor and plan to drill in from the front of the helmet, I think Cruzer pioneered that method & its the best IMO.